Adjustable roof drain

ABSTRACT

An adjustable roof drain has an extension and a base ring. An adjusting mechanism on an inner surface of the extension engages an adjusting mechanism on an outer surface of the base ring to adjustably set the position of the extension relative to the base ring. Preferably the adjusting mechanisms are threaded connections. A bead of sealant may be placed in a groove that is exposed at the joint between the two parts after the position is set.

BACKGROUND OF THE INVENTION

Roof designs can vary greatly in configuration and the type and amount of materials used. Roofs can, for example, include an insulation layer, multiple layers of flashing, and a roof deck made from various materials, typically including a sheathing and an underlayment. As a result, the thickness of roofs vary with the design and configuration. Some roof designs, flat roofs in particular, require roof drains be provided to remove water and debris that can otherwise pool and eventually damage the roof.

In order to accommodate various roof thicknesses, it is well known to provide adjustable roof drains that can be installed on roofs of different thicknesses. Conventional adjustable roof drains typically include a drain body, which is anchored to a horizontally extending roof deck. The drain body includes an outlet at its lower end which is attached to a drain pipe in the building. An adapter ring is typically mounted to the upper end of the drain body. The adapter ring has an axially extending, female threaded face and a radially extending groove for receiving an o-ring seal disposed along the face.

The conventional adjustable roof drain also includes an extension piece. The extension piece has a hollow cylindrical portion with male threads positioned along a portion of its length. The extension piece screws into the adapter ring to adjustably position the extension piece relative to the drain body. Typically the extension piece has a radially extending surface that is brought into contact with the roofing material to adjust the drain height to the intended level of the surface to be drained. The o-ring, located in the groove on the adapter ring, functions as a seal to prevent fluid from leaking out of the roof drain along the adapter ring-extension piece interface.

SUMMARY OF THE INVENTION

The present invention relates to an adjustable roof drain having an extension and a base ring. The extension includes an adjusting mechanism located on an inner surface of the extension. The base ring includes an adjusting mechanism located on an outer surface of the base ring. The adjusting mechanism of the base ring engages with the adjusting mechanism of the extension to adjustably set the position of the extension relative to the base ring.

BRIEF DESCRIPTION OF THE DRAWINGS

In the accompanying drawings which are incorporated in and constitute a part of the specification, embodiments of the invention are illustrated, which together with a general description of the invention given above and the detailed description given below, serve to exemplify this invention.

FIG. 1 is a cross sectional side view of an adjustable roof drain that is a first embodiment of the present invention.

FIGS. 2-4 are cross sectional side views of the adjustable roof drain of FIG. 1, enlarged to show various stages of mounting an extension onto a base ring of the present invention.

FIG. 5 is a cross sectional side view of an adjustable roof drain that is a second embodiment of the present invention.

DESCRIPTION OF INVENTION

The present invention relates generally to roof drains. In particular, the present invention relates to roof drains that can adjust to be installed on roofs of various thickness while providing improved sealing reliability.

FIG. 1 is a cross sectional side view of an adjustable roof drain that is a first embodiment of the present invention. The roof drain 10 includes a drain body 12, a base ring 14, an extension 16, and, optionally, a clamp ring 18. The parts of the roof drain 12 may be made from a variety of materials including metal or plastic. Preferably, the roof drain is made of coated cast iron.

The drain body 12 includes a bowl portion 20 and an outlet portion 22. The bowl portion 20 has a first sidewall 24 having a generally cylindrical configuration centered on an axis 26. The first sidewall 24 has parallel, cylindrical inner and outer side surfaces 28, 30 centered on the axis 26 and defining a flow passage 32 inward of the side wall 24.

The bowl portion 20 also has a bottom wall 34. The bottom wall 34 includes a downward sloping portion 36 connecting the bowl portion 20 to the outlet portion 22. The outlet portion 22 has a second sidewall 38 having a generally cylindrical configuration centered on the axis 26 for connecting to a drain pipe. The terms “upper” and “lower”, “inner” and “outer”, and “sides” and “end” are used herein for convenience of description and as a general reference, and do not necessarily refer to any particular orientation of the roof drain 10 when in use.

The drain body 12 has an upper end portion 40. The upper end portion 40 may include structure for securing the drain body to the roofing materials and, optionally, to the base ring 14. In the exemplary embodiment of FIG. 1, the securing structure is a radially extending flange 42. The flange 42 engages the roofing material on both an upper surface 44 and a lower surface 46 of the flange 42. The flange 42 may also include one or more fastener openings. A first fastener opening 48, for use with an associated fastener in anchoring the drain body 12 to the roof materials, may be positioned on a radially extending portion 50 of the lower surface 46. A second fastener opening 52, for use with an associated fastener in fixing the base ring 14 in position relative to the drain body 12, may be positioned along a radially extending portion 54 of the upper surface 44. The drain body 12 may include fastener openings in addition to the openings previously described. For example, additional fastener openings 48 and 52 are preferably positioned circumferentially around the drain body 12 and used with associated fasteners in to strengthen the connection between the drain body 12 and the roof materials and the base ring 14.

The base ring 14 has a first wall portion or side wall 56 having a generally cylindrical configuration centered on the axis 26. The side wall 56 has parallel, cylindrical inner and outer side surfaces 58, 60. The inner side wall surface 58 defines a flow passage 62. Preferably, but not necessarily, the base ring 14 and drain body 12 are centered on the same axis 26 such that the drain body flow passage 32 and the base ring flow passage 62 are coaxial. The base ring 14 and the drain body 12, however, may be other than coaxial.

The base ring 14 has an upper end portion 64 that is the upper end of the first side wall 56; a lower end portion 66; and a drain body engagement portion 68 for fixing the base ring 14 in position relative to the drain body 12. In the illustrated embodiment, the drain body engagement portion 68 is a radially extending surface 68 on a radially extending flange adapted to engage the radially extending upper surface 54 of the drain body 12. The drain body engagement portion 68, however, may be formed in a variety of ways in order to fix the base ring 14 in position relative to the drain body 12.

The base ring 14 includes an adjusting mechanism to enable adjustment of the position of the base ring 14 relative to the extension 16, (in a manner described below). The adjusting mechanism in the exemplary embodiment of FIG. 1 is in the form of a male thread 70 on the upper end portion 64 of the base ring 14. The adjusting mechanism is thus on an outer surface 60 of the base ring 14.

The first side wall 56 of the base ring 14 has a radially extending surface 71 and an axially extending surface 72 that partially define a groove 74 in the sidewall for receiving a sealant 76. The groove 74 faces radially outward, that is, in a direction away from the axis 26. The groove 74 is located at the upper terminal end of the sidewall 56 of the base ring 14.

The extension 16 has a lower end portion 78 and an upper end portion 80. The upper end portion 80 includes a radially extending flange 82 for engaging roof materials. The extension 16 further includes a sidewall 84 having a generally cylindrical configuration centered on the axis 26. The sidewall 84 has parallel, cylindrical inner and outer side surfaces 86, 88. The inner side surface 86 defines a flow passage 90. The extension 16 may or may not be coaxial with the drain body 12 or the base ring 14.

The extension 16 includes an adjusting mechanism 92 to enable adjustment of the axial position of the extension 16 relative to the base ring 14. The adjusting mechanism 92 in the exemplary embodiment in FIG. 1 is in the form of a female thread 92 on the sidewall 84. The female thread 92 is illustrated in FIG. 1 as extending the entire length of the inner side surface 86, from the upper end portion 80 to the lower end portion 78. The female thread 92, however, may extend only along a portion of the inner side surface 86. In addition, the adjusting mechanism of the present invention may be other than threads. For example, the adjusting mechanism may be a frictional fit between the base ring 14 and the extension 16.

In assembling the roof drain 10, the installer connects the outlet portion 22 of the drain body 12 to a drain pipe (not shown) that is installed in the building. The outlet portion 22 may connect to the drain pipe in a variety of ways. For example, the outlet portion 22 may have threads (male or female) that threadably engage corresponding female or male threads on the drain pipe. Alternatively, the drain pipe may attach to the outlet portion 22 via fasteners, a frictional fit, adhesives, clamps, or other similar means. In addition, the drain body 12 can be further attached to the roofing material (not shown) in any other manner known in the art. The securing structure 42 and fastener receiving openings on the drain body 12 facilitate its attachment to the roofing material.

The installer also attaches the base ring 14 to the drain body 12. The installer positions the lower end portion 66 of the base ring 14 adjacent to the drain bottom wall 34. The base ring lower end 66 may or may not be in contact with the drain body 12 when assembled. The drain body engagement portion 64 of the base ring 14 engages the radially extending upper surface 54 of the drain body 12. The drain body engagement portion 64 may attach to the drain body 12 by a fastener utilizing the second fastener opening 52 on the drain body 12. The base ring 14, however, may attach to the drain body 12 by means other than fasteners, such as adhesives, clamps, or other similar means.

Once the installer attaches the base ring 14 to the drain body 12 and the drain body 12 to the roofing material, the roof can be further built up. The roof is typically further built up by adding additional layers of roofing material, such as insulation and flashing, above the drain body 12.

Various stages in the attachment of the extension 16 to the base ring 14 are shown in FIGS. 2-4. After the base ring 14 and the drain body 12 are attached to each other, the installer positions the lower end portion 78 of the extension 16 adjacent to the upper end portion 64 of the base ring 14, as shown in FIG. 2. The base ring upper end portion 64 is received by the lower end portion 78 of the extension 16, as is shown in FIG. 2.

The installer partially threads the extension 16 onto the base ring 14 (FIG. 3). Prior to threading the extension 16 to its final assembled position, the installer may apply a sealant 76 to the interface between the base ring 14 and the extension 16. As shown in FIG. 3, when the extension 16 is threaded onto the base ring 14, they cooperate to fully define the groove 74. The installer places a bead of the sealant 76 into the circumferential groove 74.

Once the sealant 76 has been applied, the installer continues to thread the extension 16 onto the base ring 14 until the parts reach a final assembled position. In the final assembled position, a portion of the lower surface 94 of the radially extending flange 82 of the extension 16 contacts the additional layers of roofing materials that are placed above the drain body 12 (see FIG. 1). In this position, roofing material is captured between the extension flange 82 and the drain body flange 42, and the drain height is at the intended level of the surface to be drained.

FIG. 4 illustrates the interface between the base ring 14 and the extension 16 after the installer adjusts the roof drain 10 to the final assembled position. The sealant 76 is pulled into a portion of the threaded engagement region between the base ring 14 and the extension 16. The presence of the sealant 76 in the threaded engagement region may improve the seal between the base ring 14 and extension 16, as compared to having only the sealant 76 in the groove 74.

The installer may alternatively thread the extension 16 onto the base ring 14 to the final assembled position, prior to applying the sealant 76 into the groove 74. Although the sealant 76 is not pulled into the threaded engagement region, a satisfactory seal can still be achieved by this alternative method.

Because the female threads of the extension 16 thread onto the male threads of the base ring 14, the interface between the extension and the base ring is readily visible, and is accessible to the installer or to an inspector, from the extension passage 90. In the assembled position, the extension passage 90 and the base ring passage 62 are generally aligned. Further, the top end portion of the extension 16 is open, to provide a clear line of sight and an unobstructed path to the interface. Thus, the installer can easily reach into the passage 90 and apply the sealant 76 into the groove 74 at any point during assembly. Further, an inspector can easily visually verify the fact that the sealant 76 has been applied and can verify the quality of the seal created. Also, if required, the interface can easily be accessed later to reapply sealant.

In contrast, the conventional adjustable roof drain uses an o-ring to create a seal between an adapter ring and an extension piece. The o-ring is positioned against an outer threaded surface of the extension piece. In this position, roofing material obscures the o-ring and restricts access to it. Thus, an inspector cannot easily verify that a seal has been made and an installer cannot easily access the interface to correct sealing problems.

The roof drain 10 may optionally include a clamp ring 18 of a type known in the art. The clamp ring 18 is generally annular with a lower surface 96 that generally conforms to a portion of an upper surface 98 of the radially extending flange 82 of the extension 16. Typically, the clamp ring 18 is fixed to the flange 82 of the extension 16 via fasteners in a manner which clamps roofing material, typically flashing, between the upper surface 98 of the flange 82 and the lower surface 96 of the clamp ring.

FIG. 5 is a cross sectional side view of an adjustable roof drain 110 that is a second embodiment of the present invention. The roof drain 110 is similar to the roof drain 10 of FIGS. 1-4, and includes a base ring 114, an extension 116, and, optionally, a clamp ring 118. The exemplary roof drain 110 of FIG. 5 also includes a drain body 112 that is formed as two pieces, rather than one piece.

Specifically, the drain body 112 has a bowl portion 117 and an upper end portion 118 substantially similar to the drain body 12 of the exemplary roof drain 10 of FIGS. 1-4. The drain body 112 of FIG. 5, however, includes a modifiable outlet portion 120. The modifiable outlet portion 120 includes a base portion 122 and a first pipe connector portion 124.

The base portion 122 of the modifiable outlet portion 120 is formed with a generally cylindrical configuration centered on an axis 126. The base portion 122 includes an upper end portion 128 connected to the bowl portion 117 and a lower end portion 130 which includes fastener openings 132 along a radially extending surface 134 for connecting with the first pipe connector portion 124.

The first pipe connector portion 124 of the drain body 112 is generally funnel shaped with an upper end portion 136 which includes a radially extending flange 138 for attaching to the radially extending surface 134 of the base portion 122. The first pipe connector portion 124 also includes a lower end portion 140 formed as a generally cylindrical configuration centered on the axis 126.

In an assembled configuration, the first pipe connector portion 124 of the drain body 112 connects to a drain pipe in the same manner as described with the exemplary embodiment of FIGS. 1-4. The first pipe connector portion 124, however, is removably attached to the base portion 122. The radially extending flange 138 of the first pipe connector portion 124 engages the radially extending surface 134 on the lower end 130 of the base portion 122. Once engaged, the flange 138 and the lower end portion 130 can be attached via fasteners. As an alternative, the first pipe connector portion 124 and the base portion 122 can be threaded and be screwed together to form one unit. If the size and configuration of the drain pipe precludes readily attaching the drain pipe to the first pipe connector portion 124, a second or alternative pipe connector portion 142 (shown in dashed lines) can be provided. Because the pipe connector portion 124 is removably attached to the base portion 122, the first pipe connector portion can be easily replaced with the second pipe connector portion to allow connection to the drain pipe. A plurality of pipe connector portions can be provided with varying diameter or cross sectional shape to allow the adjustable roof drain of the present embodiment to connect to a variety of drain pipe sizes. This two piece concept is usable with apparatus other than roof drains, such as floor drains, for example. 

1. An adjustable roof drain, comprising: a drain body adapted to connect to a drain pipe; a base ring, the base ring having a first wall portion defining a first flow passage, the first wall portion having an outer surface, the outer surface having an adjusting mechanism, and the base ring having an engagement portion for connection with the drain body; and an extension that adjustably mounts onto the first wall portion of the base ring, the extension having a second wall portion defining a second flow passage, the second wall portion having an inner surface, the inner surface having an adjusting mechanism located thereon, the adjusting mechanism of the base ring being engageable with the adjusting mechanism of the extension to adjustably set the position of the extension relative to the base ring.
 2. The adjustable roof drain of claim 1 wherein the adjusting mechanism of the base ring comprises male threads and the adjusting mechanism of the extension comprises female threads.
 3. The adjustable roof drain of claim 1 wherein the engagement portion includes a radially extending flange.
 4. The adjustable roof drain of claim 1 wherein the extension further comprises a radially extending flange for engaging roofing material.
 5. The adjustable roof drain of claim 1 wherein the inner surface of the extension and the outer surface of the base ring operably form a circumferential groove for receiving sealant material.
 6. The adjustable roof drain of claim 1 wherein a sealant groove is formed around an upper end portion of the base ring.
 7. The adjustable roof drain of claim 1 wherein the drain body is made from a support portion and a first pipe connector portion, the first pipe connector portion being removably attached to the support portion and replaceable with a second pipe connector portion for modifying the drain body to connect to a different drain pipe configuration.
 8. A roof drain that can adjust for installation on roofs with roof materials of different thickness, the roof drain comprising: a drain body having an outlet portion and an upper end portion, the outlet portion having a generally cylindrical sidewall centered on an axis for connecting to a drain pipe, the upper end portion including a first radially extending flange for engaging the roofing material; a base ring having a first wall portion, a second radially extending flange, and an upper end portion, the first wall portion having a generally cylindrical configuration centered on the axis with parallel, cylindrical inner and outer side surfaces defining a first flow passage, the second radially extending flange adapted to engage a radially extending upper surface of the drain body, the upper end portion having male threads along an outer surface; and an extension having a second wall portion with a generally cylindrical configuration centered on an axis with parallel, cylindrical inner and outer side surfaces defining a second flow passage, the inner side surface including female threads to threadably engage the male threads of the base ring to adjustably position the extension relative to the axial position of the base ring.
 9. A method of installing an adjustable roof drain, comprising the steps of: mounting a drain body to a drain pipe; mounting a base ring having an adjusting mechanism on an outer surface to the drain body; engaging an extension having an adjusting mechanism on an inner surface with the adjusting mechanism of the base ring; and adjusting the axial position of the extension relative to the base ring.
 10. The method of claim 9 wherein the inner surface of the extension and the outer surface of the base ring operably form a circumferential groove for receiving sealant material and further comprising the step of: applying sealant into the circumferential groove to effect a seal between the extension and the base ring.
 11. The method of claim 9 further comprising the step of: installing roofing materials onto the roof after the step of mounting the base ring to the drain body; installing a membrane to cover the roofing materials after the step of adjusting the axial position of the extension relative to the base ring; and mounting a clamp ring onto the extension to secure the membrane between the clamp ring and the extension.
 12. The method of claim 9 wherein the adjusting mechanism on the inner surface of the extension includes female threads and the adjusting mechanism on the outer surface of the base ring includes male threads.
 13. The method of claim 12 further wherein the step of adjusting the axial position of the extension relative to the base ring comprises: screwing the extension partially onto the base ring, applying sealant to a groove operably formed by the inner surface of the extension and the outer surface of the base ring, and continuing to screw the extension onto the base ring until an upper surface of the extension contacts the roofing materials. 